Footwear inserts, including midsoles, sockliners, footbeds and/or upper components using granular ethyl vinyl acetate (EVA) and method of manufacture

ABSTRACT

Shoe inserts, including midsoles, footbeds, sockliners and/or upper components with a moldable outer membrane having an upper portion and a bottom portion, with the bottom portion being injected through an injection means with one or more layers of granular ethyl vinyl acetate through one or more compartments located inside of the outer membrane, the layers of granular ethyl vinyl acetate being of various densities to fit the particular application, the granular ethyl vinyl acetate being produced through the breaking down of the physical state of solid foam ethyl vinyl acetate and with the granular ethyl vinyl acetate optionally containing on or more variety of colors.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to the field of shoe inserts, including midsoles, footbeds and/or upper components, designed for comfort, ranging from the casual shoe to the athletic shoe and a method for manufacturing same.

2. Description of the Prior Art

Shoe inserts, including midsoles, sockliners, footbeds and upper components, are well-known in the art as articles added to shoes both for comfort and improved athletic performance, among other things. Many people do not have proper alignment in their feet for the proper gait needed for optimal alignment and health. For these people, modifications to their footwear are needed. A common modification for this purpose is the addition of inserts, including midsoles, footbeds, sockliners and/or upper components of one type or another, including those that can correct misalignment and improve, comfort, walking and athletic performance.

Shoe inserts, including midsoles, footbeds, sockliners and/or upper components of any one of these types containing fillers are known in the art. For examples, see U.S. Pat. Nos. 5,150,490, 4,658,515, 5,864,968 and 6,782,640.

U.S. Pat. No. 6,170,177 to Frappier teaches of a shoe that has a moldable, settable midsole. In the Frappier invention, the midsole of a shoe is set by an injection apparatus that injects a settable fluid, such as polyurethane or ethyl vinyl acetate (EVA) foam.

The instant invention seeks to improve on the prior art by providing inserts, such as midsoles, footbeds, sockliners and/or upper components that have a controlled compression set, shock absorption with energy return, density control that is dependent upon application (whether it is for a casual shoe or an athletic shoe), and has multiple density application that can be injected into one or more layers into one or more compartments in the inserts, such as midsoles, footbeds, sockliners and/or upper components. Furthermore, the instant invention can involve the addition of multiple colors of the inserts, such as midsoles, footbeds, sockliners and/or upper components, added for attractiveness and decoration. These objectives are achieved through the filling of the inserts, such as midsoles, footbeds, sockliners and/or upper components with granular ethyl vinyl acetate (EVA). EVA is essentially a foam in which for this patent has been broken down into a physical granular state that more resembles dust.

SUMMARY OF THE INVENTION

In the preferred embodiment of the present invention, inserts, such as midsoles, footbeds, sockliners and/or upper components, for a shoe and a method for making same is disclosed that includes inserts, such as midsoles, footbeds, sockliners and/or upper components, with an outer membrane that is moldable into a desired shape. The outer membrane has an upper portion and a bottom portion. Granular ethyl vinyl acetate created by breaking down foam ethyl vinyl acetate is blown into the bottom portion of the outer membrane through a direct injection process.

Yet another embodiment of the above invention modifies the above embodiment by defining that the outer membrane is made of thermal polyurethane.

Yet another embodiment of the above invention modifies the above embodiment by defining that the outer membrane is made of elastomeric silicone.

Yet another embodiment of the above invention modifies the above embodiment by defining that the granular ethyl vinyl acetate is housed in one or more compartments inside of the outer membrane.

Yet another embodiment of the above invention modifies the above embodiment by defining that the granular ethyl vinyl acetate can be multi-colored and come in multiple densities.

A second embodiment involves the method of manufacturing the shoe inserts, such as midsoles, footbeds, sockliners and/or upper components, involves the steps of molding an outer membrane from a mold, with the mold being of a variable shape. The outer membrane has an upper portion and bottom portion. Solid ethyl vinyl acetate is broken down into a granular state. The granular ethyl vinyl acetate is then blown into the bottom portion of the outer membrane through a direct injection process.

Yet another embodiment of the second embodiment above further modifies the second embodiment by defining that the outer membrane is made of thermal polyurethane.9

Yet another embodiment of the second embodiment above further modifies the second embodiment by defining that the outer membrane is made of elastomeric silicone.

Yet another embodiment of the second embodiment above further modifies the second embodiment by defining that the granular ethyl vinyl acetate is housed in one or more compartments inside of the outer membrane.

Yet another embodiment of the second embodiment above further modifies the second embodiment by further defining that the granular ethyl vinyl acetate can be multi-colored and come in multiple densities.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of one of the inserts, such as a midsole, footbed and/or a sockliner.

FIG. 2 is a side cross-sectional view taken on line 2-2 of FIG. 1 of an insert, such as a midsole, footbed and/or a sockliner with the granular ethyl vinyl acetate being present in one compartment located in the interior of the inserts, including midsoles, footbeds, sockliners and/or upper components.

FIG. 3 is a side view similar to FIG. 2 of the inserts, including midsoles, footbeds, sockliners and/or upper components with the granular ethyl vinyl acetate being present in two compartments located in the interior of the inserts, including midsoles, footbeds, sockliners and/or upper components.

FIG. 3A is a cross-sectional view as defined in FIG. 3 by the arrows marked 3A, showing a close-up view of the granular ethyl vinyl acetate.

FIG. 4 is a top perspective view of the insert prior to be compressed by a foot.

FIG. 5 is a top perspective view of the insert with the presence of a human foot exerting pressure thereon.

FIG. 6 is taken along the line 6-6 on FIG. 5 and shows a side view of the insert and how is compressed with the presence of a human foot exerting pressure thereon.

FIG. 7 is a top perspective view of the insert after the foot has exerted pressure thereon and subsequently removed.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

Referring now to the drawings. FIG. 1 shows one of the inserts 10, including midsoles, footbeds, sockliners and/or upper components 10 from the top. As seen in FIGS. 2 and 3, the insert 10, which is transparent, including midsoles, footbeds, sockliners and/or upper components is composed of a thin outer membrane 15 that is typically made from a flexible material, such as thermal polyurethane or elastomeric silicone.

The side views shown in FIGS. 2 and 3, along with the cross-sectional view shown in FIG. 3A demonstrates how the granular particles 20 are positioned inside the outer membrane 15.

FIG. 2 shows one interior compartment 16 a wherein granular ethyl vinyl acetate 20 is injected into the interior compartment 16 a. FIG. 3 demonstrates how a second interior compartment 16 b can be utilized to prepare the inserts 10, including midsoles, footbeds, sockliners and/or upper components with more than one interior compartment for the desired comfort level and density of the inserts 10, including midsoles, footbeds, sockliners and/or upper components.

The sequence of FIGS. 4-7 show the effect of the pressure of the human foot 11 as it presses onto the insert 10. Prior to the exertion of pressure, the insert 10 has a flat surface 12. Once the foot 11 steps on the insert 10, the granular ethyl vinyl acetate 20 molds to the shape of the heel 13, arch 14 and toes 16. As seen in FIG. 7, once the foot 11 is removed from the insert 10, depressions are left on the shaped surface 17 of the insert 10.

In addition to a variable density of granular ethyl vinyl acetate 20 in the inserts 10, including midsoles, footbeds, sockliners and/or upper components, the ethyl vinyl acetate 20 can be manufactured in a variety of colors that can be seen through the transparent insert. Single colors and color blends can be added to a single compartment 16 a. Similarly, any desired color combination can be added to multiple compartments 16 a, 16 b.

The illustrations and examples provided herein are for explanatory purposes and are not intended to limit the scope of the appended claims. This disclosure is to be considered an exemplification of the principles of the invention and is not intended to limit the spirit and scope of the invention and/or claims of the embodiment illustrated. Those skilled in the art will make modifications to the invention for particular applications of the invention. 

1. An insert, such as a midsole, footbed, sockliner and/or upper component for a shoe comprising: an outer membrane moldable into a desired shape said outer membrane having an upper portion and a bottom portion; granular ethyl vinyl acetate said granular ethyl vinyl acetate being created by the breaking down of foam ethyl vinyl acetate; means for injecting said granular ethyl vinyl acetate into said bottom portion of said outer membrane.
 2. An insert, such as a midsole, footbed, sockliner and/or upper component for a shoe as defined in claim 1 wherein said outer membrane is made of thermal polyurethane.
 3. An insert, such as a midsole, footbed, sockliner and/or upper component for a shoe as defined in claim 1 wherein said outer membrane is made of elastomeric silicone.
 4. An insert, such as a midsole, footbed, sockliner and/or upper component for a shoe as defined in claim 1 wherein said granular ethyl vinyl acetate is housed in one or more compartments inside of said outer membrane.
 5. An insert, such as a midsole, footbed, sockliner and/or upper component for a shoe as defined in claim 1 wherein said granular ethyl vinyl acetate can be multi-colored.
 6. An insert, such as a midsole, footbed, sockliner and/or upper component for a shoe as defined in claim 1 wherein said granular ethyl vinyl acetate can be applied in multiple densities.
 7. A method for manufacturing a shoe insert, such as a midsole, footbed, sockliner and/or upper component comprising: molding an outer membrane from a mold, said mold being of a variable shape said outer membrane having an upper portion and bottom portion; breaking down solid ethyl vinyl acetate from a solid state to a granular state; injecting said granular ethyl vinyl acetate into said bottom portion of said outer membrane through an injection means.
 8. A method as defined in claim 7 wherein said outer membrane is made of thermal polyurethane.
 9. A method as defined in claim 7 wherein said outer membrane is made of elastomeric silicone.
 10. A method as defined in claim 7 wherein said granular ethyl vinyl acetate is housed in one or more compartments inside of said outer membrane.
 11. A method as defined in claim 7 wherein said granular ethyl vinyl acetate can be multi-colored.
 12. A method as defined in claim 7 wherein said granular ethyl vinyl acetate can be applied in multiple densities. 